Wire Guide System for Hand Tools

Abstract

A system for attaching electrical terminals to wires includes a wire guide cassette removably affixed to a crimping tool, the wire guide cassette movable between at least a closed position and an open position, wherein in the open position, an end terminal may be inserted through a wire guide orifice and into the crimping tool. In the closed position, a wire may be inserted into the wire guide orifice and into the end terminal. The wire guide cassette locates and aligns the wire for insertion into the end terminal in the closed position, wherein the crimping tool may then be used to crimp the end terminal onto the wire. The wire guide cassette may then be opened, and the wire and end terminal crimped to the wire may be removed from the wire guide cassette and tool.

What is claimed is: 
     
         1 . A system for attaching electrical terminals to wires comprises:
 a wire guide cassette; and   a crimping tool, wherein the wire guide cassette is removably mounted to the crimping tool, wherein the wire guide cassette is movable between at least a closed position and an open position displaced from the closed position, wherein the wire guide cassette is movable independent from crimping actuation of the crimping tool, wherein a wire inserted into the wire guide cassette in the closed position is located and guided into an end terminal held in the crimping tool, and the crimping tool is actuated to crimp the end terminal onto a stripped end of the wire, and wherein in the open position, the wire and end terminal are freely movable relative to and removable from the wire guide cassette and crimping tool.   
     
     
         2 . The system of  claim 1 , wherein the wire guide cassette further comprises:
 a mounting plate affixed coaxially to the crimping tool by one or more mounting plate fasteners;   a lower lift plate coaxially disposed overtop the mounting plate opposite the crimping tool;   one or more ball bearings disposed in ramps formed in the lower lift plate opposite the crimping tool;   a bearing retainer plate disposed overtop and coaxially located with the lower lift plate and the mounting plate, the bearing retainer plate movably retaining the one or more ball bearings;   a lower carriage plate coaxially disposed overtop the bearing retainer plate;   a plurality of wire guide portions disposed overtop the bearing retainer plate, the plurality of wire guide portions defining a wire guide cone tip extending coaxially through each of the lower carriage plate, the bearing retainer plate, the lower lift plate, the mounting plate, and into the crimping tool;   an upper carriage plate disposed overtop the plurality of wire guide portions, and located coaxially with the lower carriage plate, the bearing retainer plate, the lower lift plate, the mounting plate, and the crimping tool;   a washer disposed coaxially overtop the upper carriage plate;   a cover plate disposed coaxially overtop the upper carriage plate and secured to the upper carriage plate, the lower carriage plate, the bearing retainer plate, the lower lift plate and the mounting plate with one or more cover plate fasteners; and   an activation ring circumferentially surrounding at least the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate, wherein the activation ring is locked for rotational movement in concert with the bearing retainer plate, wherein as the activation ring is moved from the closed position to the open position, the activation ring causes rotational and axial movement of the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate relative to the mounting plate and the crimping tool, wherein the axial movement defines an increase in axial distance between the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate and the mounting plate and crimping tool.   
     
     
         3 . The system of  claim 2 , wherein:
 the ramps formed in the lower lift plate are substantially tear-drop shaped depressions having a variable depth which decreases from a substantially circular head to a pointed tail of the ramp, wherein the heads and tails of the ramps are circumferentially-disposed at equidistant locations about an outer surface of the lower lift plate, wherein the outer surface of the lower lift plate faces away from the mounting plate and the crimping tool;   the bearing retainer plate is disposed overtop the lower lift plate and movably retains the one or more ball bearings at the equidistant locations; and   the lower carriage plate has a plurality of mirrored ramps are formed on an inner side of the lower carriage plate at substantially identical circumferential positions as the ramps formed in the lower lift plate and bearing retainers formed through the bearing retainer plate, wherein the inner side of the lower carriage plate faces towards the mounting plate and the crimping tool; and wherein the mirrored ramps define substantially tear-drop shaped depressions having a variable depth which decreases from a substantially circular “head” to a pointed “tail” of the mirrored ramp; and   the mirrored bearing ramps are oriented opposite the ramps such that the heads and tails of the ramps extend in circumferentially opposite directions to the heads and tails of the mirrored ramps.   
     
     
         4 . The system of  claim 3 , wherein the ramps and mirrored ramps have a maximum depth at the heads of the ramps and mirrored ramps, and a minimum depth, smaller than the maximum depth, at the tails of the ramps and mirrored ramps. 
     
     
         5 . The system of  claim 4 , wherein as the activation ring is moved from the closed position to the open position, rotational movement of the activation ring causes rotational movement of the bearing retainer plate which thereby causes the ball bearings to ride within the ramps and mirrored ramps from the heads of the ramps and mirrored ramps to the tails of the ramps and mirrored ramps, thereby increasing an axial distance between the lower carriage plate and the lower lift plate from a minimum distance to a maximum distance larger than the minimum distance, wherein the maximum distance is substantially identical to a diameter of the ball bearings. 
     
     
         6 . The system of  claim 2 , wherein the plurality of wire guide portions further comprise:
 a first wire guide portion; and   a second wire guide portion identical to the first wire guide portion, wherein each of the first and second wire guide portions are rotatably attached to the upper and lower carriage plates by dowels extending from the lower carriage plate through the first and second wire guide portions and into the upper carriage plate, and wherein the first wire guide portion has a first diametric face, and the second wire guide portions has a second diametric face, wherein in the closed position, the first and second diametric faces are in contact with one another.   
     
     
         7 . The system of  claim 6 , further comprising:
 one or more return springs, the one or more return springs biasing the first and second diametric faces into contact with one another.   
     
     
         8 . The system of  claim 7 , wherein each of the one or more return springs is in contact with and extends from an outer spring seat formed as an axial protrusion on the lower carriage plate to an inner spring seat formed on each of the first and second wire guide portions. 
     
     
         9 . The system of  claim 2 , wherein the washer biases the cover plate against the upper carriage plate, thereby providing a compacting force that secures all component parts of the wire guide cassette against one another within the activation ring and against the crimping tool. 
     
     
         10 . The system of  claim 9 , wherein the washer is formed of spring steel and defines a wave washer. 
     
     
         11 . A wire guide system for hand tools, wherein the wire guide system comprises:
 a wire guide cassette; and   a crimping tool, wherein a mounting plate of the wire guide cassette is removably and coaxially affixed to the crimping tool by one or more mounting plate fasteners, and wherein the wire guide cassette further comprises:
 a mounting plate affixed coaxially to the crimping tool by one or more mounting plate fasteners; 
 a lower lift plate coaxially disposed overtop the mounting plate opposite the crimping tool; 
 one or more ball bearings disposed in ramps formed in the lower lift plate opposite the crimping tool; 
 a bearing retainer plate disposed overtop and coaxially located with the lower lift plate and the mounting plate, the bearing retainer plate movably retaining the one or more ball bearings; 
 a lower carriage plate coaxially disposed overtop the bearing retainer plate; 
 a plurality of wire guide portions disposed overtop the bearing retainer plate, the plurality of wire guide portions defining a wire guide cone tip extending coaxially through each of the lower carriage plate, the bearing retainer plate, the lower lift plate, the mounting plate, and into the crimping tool; 
 an upper carriage plate disposed overtop the plurality of wire guide portions, and located coaxially with the lower carriage plate, the bearing retainer plate, the lower lift plate, the mounting plate, and the crimping tool; 
 a washer disposed coaxially overtop the upper carriage plate; 
 a cover plate disposed coaxially overtop the upper carriage plate and secured to the upper carriage plate, the lower carriage plate, the bearing retainer plate, the lower lift plate and the mounting plate with one or more cover plate fasteners; and 
 an activation ring circumferentially surrounding at least the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate, wherein the activation ring is locked for rotational movement in concert with the bearing retainer plate, wherein as the activation ring is moved from a closed position to an open position, the activation ring causes rotational and axial movement of the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate relative to the mounting plate and the crimping tool, wherein the axial movement defines an increase in axial distance between the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate and the mounting plate and crimping tool; and wherein the wire guide cassette is movable, via actuation of the actuation ring, independent from crimping actuation of the crimping tool, wherein a wire inserted into the wire guide cassette in the closed position is located and guided into an end terminal held in the crimping tool, and the crimping tool is actuated to crimp the end terminal onto a stripped end of the wire, and wherein in the open position, the wire and end terminal are freely movable relative to and removable from the wire guide cassette and crimping tool. 
   
     
     
         12 . The system of  claim 11 , wherein:
 the ramps formed in the lower lift plate are substantially tear-drop shaped depressions having a variable depth which decreases from a substantially circular head to a pointed tail of the ramp, wherein the heads and tails of the ramps are circumferentially-disposed at equidistant locations about an outer surface of the lower lift plate, wherein the outer surface of the lower lift plate faces away from the mounting plate and the crimping tool;   the bearing retainer plate is disposed overtop the lower lift plate and movably retains the one or more ball bearings at the equidistant locations; and   the lower carriage plate has a plurality of mirrored ramps are formed on an inner side of the lower carriage plate at substantially identical circumferential positions as the ramps formed in the lower lift plate and bearing retainers formed through the bearing retainer plate, wherein the inner side of the lower carriage plate faces towards the mounting plate and the crimping tool; and wherein the mirrored ramps define substantially tear-drop shaped depressions having a variable depth which decreases from a substantially circular “head” to a pointed “tail” of the mirrored ramp;   the mirrored bearing ramps are oriented opposite the ramps such that the heads and tails of the ramps extend in circumferentially opposite directions to the heads and tails of the mirrored ramps; and wherein the ramps and mirrored ramps have a maximum depth at the heads of the ramps and mirrored ramps, and a minimum depth, smaller than the maximum depth, at the tails of the ramps and mirrored ramps.   
     
     
         13 . The system of  claim 12 , wherein as the activation ring is moved from the closed position to the open position, rotational movement of the activation ring causes rotational movement of the bearing retainer plate which thereby causes the ball bearings to ride within the ramps and mirrored ramps from the heads of the ramps and mirrored ramps to the tails of the ramps and mirrored ramps, thereby increasing an axial distance between the lower carriage plate and the lower lift plate from a minimum distance to a maximum distance larger than the minimum distance, wherein the maximum distance is substantially identical to a diameter of the ball bearings. 
     
     
         14 . The system of  claim 11 , wherein the plurality of wire guide portions further comprise:
 a first wire guide portion; and   a second wire guide portion identical to the first wire guide portion, wherein each of the first and second wire guide portions are rotatably attached to the upper and lower carriage plates by dowels extending from the lower carriage plate through the first and second wire guide portions and into the upper carriage plate, and wherein the first wire guide portion has a first diametric face, and the second wire guide portions has a second diametric face, wherein in the closed position, the first and second diametric faces are in contact with one another.   
     
     
         15 . The system of  claim 14 , further comprising:
 one or more return springs, the one or more return springs biasing the first and second diametric faces into contact with one another so that wires inserted into the wire guide cassette in the closed position are located and guided into the end terminal held in the crimping tool.   
     
     
         16 . The system of  claim 15 , wherein each of the one or more return springs is in contact with and extends from an outer spring seat formed as an axial protrusion on the lower carriage plate to an inner spring seat formed on each of the first and second wire guide portions. 
     
     
         17 . The system of  claim 11 , wherein the washer biases the cover plate against the upper carriage plate, and provides a compacting force that secures all component parts of the wire guide cassette against one another within the activation ring and against the crimping tool. 
     
     
         18 . A method for attaching electrical terminals to wires comprises:
 removably mounting a wire guide cassette onto a crimping tool, wherein the wire guide cassette is movable between at least a closed position and an open position displaced from the closed position, wherein the wire guide cassette is movable independently from crimping actuation of the crimping tool;   inserting a wire into the wire guide cassette in the closed position, wherein in the closed position the wire is located and guided into an end terminal held in the crimping tool;   actuating the crimping tool to crimp the end terminal onto a stripped end of the wire; and   moving the wire guide cassette to the open position, wherein in the open position the wire and end terminal are freely movable relative to and removable from the wire guide cassette and crimping tool.   
     
     
         19 . The method of  claim 18  wherein removably mounting the wire guide cassette onto the crimping tool further comprises:
 coaxially affixing a mounting plate of the wire guide cassette to the crimping tool with one or more mounting plate fasteners, wherein the wire guide cassette further includes:
 a lower lift plate coaxially disposed overtop the mounting plate opposite the crimping tool; 
 one or more ball bearings disposed in ramps formed in the lower lift plate opposite the crimping tool, wherein the ramps formed in the lower lift plate are substantially tear-drop shaped depressions having a variable depth which decreases from a substantially circular head to a pointed tail of the ramp, wherein the heads and tails of the ramps are circumferentially-disposed at equidistant locations about an outer surface of the lower lift plate, wherein the outer surface of the lower lift plate faces away from the mounting plate and the crimping tool; 
 a bearing retainer plate disposed overtop and coaxially located with the lower lift plate and the mounting plate, the bearing retainer plate movably retaining the one or more ball bearings; 
 a lower carriage plate coaxially disposed overtop the bearing retainer plate, wherein a plurality of mirrored ramps are formed on an inner side of the lower carriage plate at substantially identical circumferential positions as the ramps formed in the lower lift plate and bearing retainers formed through the bearing retainer plate, wherein the inner side of the lower carriage plate faces towards the mounting plate and the crimping tool; and wherein the mirrored ramps define substantially tear-drop shaped depressions having a variable depth which decreases from a substantially circular “head” to a pointed “tail” of the mirrored ramp, wherein the mirrored bearing ramps are oriented opposite the ramps such that the heads and tails of the ramps extend in circumferentially opposite directions to the heads and tails of the mirrored ramps, wherein the ramps and mirrored ramps have a maximum depth at the heads of the ramps and mirrored ramps, and a minimum depth, smaller than the maximum depth, at the tails of the ramps and mirrored ramps; 
 a first wire guide portion and a second wire guide portion identical to the first wire guide portion, the first and second wire guide portions disposed overtop the bearing retainer plate, the first and second wire guide portions defining a wire guide cone tip extending coaxially through each of the lower carriage plate, the bearing retainer plate, the lower lift plate, the mounting plate, and into the crimping tool; 
 an upper carriage plate disposed overtop the first and second wire guide portions, and located coaxially with the lower carriage plate, the bearing retainer plate, the lower lift plate, the mounting plate, and the crimping tool, wherein each of the first and second wire guide portions are rotatably attached to the upper and lower carriage plates by dowels extending from the lower carriage plate through the first and second wire guide portions and into the upper carriage plate, and wherein the first wire guide portion has a first diametric face, and the second wire guide portion has a second diametric face, wherein in the closed position, the first and second diametric faces are in contact with one another; 
 a washer disposed coaxially overtop the upper carriage plate; 
 a cover plate disposed coaxially overtop the upper carriage plate and secured to the upper carriage plate, the lower carriage plate, the bearing retainer plate, the lower lift plate and the mounting plate with one or more cover plate fasteners; and 
 an activation ring circumferentially surrounding at least the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate, wherein the activation ring is locked for rotational movement in concert with the bearing retainer plate; 
 one or more return springs, wherein each of the one or more return springs is in contact with and extends from an outer spring seat formed as an axial protrusion on the lower carriage plate to an inner spring seat formed on each of the first and second wire guide portions; and 
 
 causing, by moving the activation ring, rotational movement of the bearing retainer plate and in turn, causing the ball bearings to ride within the ramps and mirrored ramps from the heads of the ramps and mirrored ramps to the tails of the ramps and mirrored ramps, thereby increasing an axial distance between the lower carriage plate and the lower lift plate from a minimum distance to a maximum distance larger than the minimum distance, wherein the maximum distance is substantially identical to a diameter of the ball bearings, wherein moving the activation ring from the closed position to the open position causes rotational and axial movement of the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate relative to the mounting plate and the crimping tool, wherein the axial movement defines an increase in axial distance between the bearing retainer plate, the lower carriage plate, the one or more wire guide portions, and the upper carriage plate and the mounting plate and crimping tool. 
 
     
     
         20 . The method of  claim 19  wherein
 biasing, via the one or more return springs, the first and second diametric faces into contact with one another, 
 biasing, via the washer, the cover plate against the upper carriage plate, and providing a compacting force that secures all component parts of the wire guide cassette against one another within the activation ring and against the crimping tool.